<4>How do you create an archway in a concrete wall?
Expanded Polystyrene block-outs, sandwiched between two straight concrete forms, are the easiest, most cost-effective way to create any unique shape in a concrete wall. Six archways, in this Sea Island, Georgia resort, were created using .9 lb. density EPS. Two pieces were used across the bottom and one radiused piece for the top. The wall is 12” thick and the finished arches are 6’ 4” wide and just under 12’ tall. The contractor secured the EPS blocks between straight forms before pumping the concrete. EPS block-outs like these are generally not reusable but many applications are designed so the foam can be reused multiple times.
Universal Foam Products has a patented system for attaching EPS
block-outs and form liners to contractor forms, that allows for easy
removal after the pour.